JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD

Overview

Course objectives: This course is mainly designed to provide knowledge about various metal forming operations, their process parameters, and mathematical equations associated with the process.

Course outcomes: After completing the course, the student will be able

• 1. To choose the best forming process for a specific product.
• 2. Use the Mohr’s circle to graphically analyze stresses and strains;
• 3. Analyze, compare and finally gain theoretical experience for the advantages and limitations of different manufacturing processes
• 4. To practically appreciate the utilization of these fundamentals in industrial manufacturing processes.
• 5. To analyze metallurgical and mechanical aspects of forming of metals into useful shapes and properties.

UNIT - I

Stress and Strain Relationship for Elastic Behavior: Description of stress at a point. State of stress in two dimensions. Mohrs circle of stress in two dimensions, state of stress in three dimensions. Mohrs circle of stress in three dimensions. Description of strain at point.

UNIT - II

Elements of Theory of Plasticity: The flow curve. True stress and true strain. Von-Mises distortion energy criterion, maximum shear stress or Tresca criterion. Octahedral shear stress and shear strain. Basics of the theories of plasticity.

UNIT - III

Fundamentals of Metal Working: Classification of forming processes, Mechanics of metal working for slab method and uniform deformation energy method. Cold working, Recovery, recrystallization and grain growth, hot working, Strain-Rate effects, Work of plastic deformation. Forging: Classification of forging processes, forging equipment. Forging in plane strain. Open-die forging, closed-die forging, Forging of a cylinder in plane-strain. Forging defects,

UNIT - IV

Rolling of Metals: Classification of rolling process, rolling mills. Hot rolling, cold rolling, rolling of bars and shapes, forging and geometrical relationships in rolling. Simplified analysis of rolling load, rolling variables, problems and defects in rolled products. Theories of hot rolling, torque and horsepower, theories of cold rolling, torque and horsepower.

UNIT - V

Extrusion: Classification of extrusion processes, extrusion equipment. Hot extrusion. Deformation and defects in extrusion. Analysis of the extrusion process. Cold extrusion. Extrusion of tubing and production of seamless pipe and tubing. Drawing of Rods, Wires and Tubes: rod and wire drawing, tube drawing processes, deep drawing, residual stresses in rod, wire and tubes.

TEXT BOOKS:

• 1. Mechanical Metallurgy by GE Dieter (3rd edition)
• 2. Technology of Metal forming Processes – Surendra Kumar PHI 2008
• 3. Metal Forming: Mechanics and Metallurgy by William F. Hosford and Robert M. Caddel (4th edition), Cambridge University Press R18 B.TECH MME III YEAR

REFERENCE BOOKS:

• 1. Mechanical working of metals-Avitzur.
• 2. Engineering Metallurgy-PartII-Higgins.
• 3. Mechanical Metallurgy- White and Lemay. R18 B.TECH MME III YEAR